HYBRID PRESSURIZED AND NON-PRESSURIZED LUBRICATION SYSTEM FOR AIRCRAFT GEARBOX
In some examples, an aircraft gearbox comprises a plurality of gears and a hybrid lubrication system to lubricate the plurality of gears. The plurality of gears comprises a first gear and a second gear. The plurality of gears operable to rotate based on torque received from a driveshaft. The hybrid lubrication system comprises a pressurized lubrication system and a non-pressurized lubrication system. The pressurized lubrication system comprises a nozzle to spray a lubricant onto the first gear. The non-pressurized lubrication system comprises a reservoir to catch a portion of the lubricant from the pressurized lubrication system. The second gear is operable to disperse the lubricant across others of the plurality of gears based on the second gear rotating through the portion of the lubricant.
This disclosure relates generally to transmission systems, and more particularly, though not exclusively, to systems and apparatuses for cooling a gear in a transmission system.
BACKGROUNDAircraft include many components and systems that are powered by an engine. For example, an engine provides power to flight-critical components such as rotors, which keep the aircraft airborne during flight, and to auxiliary systems such as fans, blowers, pumps, generators, and interior climate control systems, which may control non-flight-critical components. The engine provides power to the components and systems through a drive system. The drive system includes, e.g., masts, driveshafts, bearings, and gears which transfer torque from the engine to the components and systems. A lubrication system lubricates the drive system. The lubrication helps protect components of the drive system from wear and facilitates movement of the components so that they effectively transfer torque. In some drive systems, the components may rotate at thousands of revolutions per minute (RPM) during operation and generate heat. The lubrication system can transfer heat from the drive system and cool the components. For example, a pressurized lubrication system can use pressure to spread a lubricant on the drive system. When properly functioning, the lubrication system can reduce the likelihood of the drive system losing torque, failing, and/or overheating. The drive system is more susceptible to losing torque, failing (in whole or in part), and/or overheating when the lubrication system is malfunctioning and/or not functioning at all. Thus, maintaining a properly functioning lubrication system is critical to the safety and the service life of the aircraft.
SUMMARYIn some examples, a gearbox includes a plurality of gears and a hybrid lubrication system to lubricate the plurality of gears. The plurality of gears includes a first gear and a second gear. The plurality of gears is operable to rotate based on torque received from a driveshaft. The hybrid lubrication system includes a pressurized lubrication system and a non-pressurized lubrication system. The pressurized lubrication system includes a nozzle to spray a lubricant onto the first gear. The non-pressurized lubrication system includes a reservoir to catch a portion of the lubricant from the pressurized lubrication system. The second gear is operable to disperse the lubricant across others of the plurality of gears based on the second gear rotating through the portion of the lubricant.
In other examples, an aircraft includes an engine, a driveshaft coupled to the engine, and a gearbox coupled to the driveshaft. The gearbox includes a plurality of gears operable to rotate based on torque received from the driveshaft and a hybrid lubrication system operable to lubricate the plurality of gears. The plurality of gears includes a first gear and a second gear. The hybrid lubrication system includes a pressurized lubrication and a non-pressurized lubrication. The pressurized lubrication system includes a nozzle operable to spray a lubricant onto the first gear. The non-pressurized lubrication system includes a reservoir operable to catch a portion of the lubricant from the pressurized lubrication system. The second gear is operable to disperse the lubricant onto others of the plurality of gears based on rotating through the portion of the lubricant.
In still other examples, a method includes providing an aircraft gearbox comprising a plurality of gears and lubricating the plurality of gears with a hybrid lubrication system. The plurality of gears includes a first gear and a second gear. The hybrid lubrication system includes a pressurized lubrication system and a non-pressurized lubrication system. The method further includes: spraying, by a nozzle in the pressurized lubrication system, a lubricant onto the first gear; catching, by a reservoir in the non-pressurized lubrication system, a portion of the lubricant from the pressurized lubrication system; and dispersing the lubricant onto others of the plurality of gears based on the second gear rotating through the portion of the lubricant.
The following disclosure describes various illustrative embodiments and examples for implementing the features and functionality of the present disclosure. While particular components, arrangements, and/or features are described below in connection with various example embodiments, these are merely examples used to simplify the present disclosure and are not intended to be limiting. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, including compliance with system, business, and/or legal constraints, which may vary from one implementation to another. Moreover, it will be appreciated that, while such a development effort might be complex and time-consuming, it would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present disclosure, the devices, components, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” or other similar terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components, should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the components described herein may be oriented in any desired direction.
Example embodiments that may be used to implement the features and functionality of this disclosure will now be described with more particular reference to the attached Figures.
The drive system 113 is substantially symmetric to the drive system 111. Only for the sake of brevity, certain features will be disclosed only with regard to drive system 111. However, one of ordinary skill in the art will fully appreciate an understanding of the drive system 113 based upon the disclosure herein of the drive system 111.
Further, drive systems 111 and 113 are illustrated in the context of tiltrotor aircraft 100; however, drive systems 111 and 113 can be implemented on other tiltrotor aircraft. For example, an alternative embodiment may include a quad tiltrotor that has an additional wing member aft of wing 109; the additional wing member can have additional drive systems similar to drive systems 111 and 113. In another embodiment, drive systems 111 and 113 can be used with an unmanned version of tiltrotor aircraft 100. Further, drive systems 111 and 113 can be integrated into a variety of tiltrotor aircraft configurations. Additionally, other drive systems are contemplated. For example, in some embodiments a gearbox arrangement provides torque to a rotor system of a helicopter.
It should be appreciated that the tiltrotor aircraft 100 of
When properly functioning, a pressurized lubrication system can reduce the likelihood of a drive system such as the drive systems 111 and/or 233 from losing torque, failing, and/or overheat. For example, the pressurized lubrication system may operate properly when the pressure is maintained above a threshold pressure limit such as about 30 pounds per square inch (PSI) or about 50 PSI. A drive system is more susceptible to losing torque, failing (in whole or in part), and/or overheating when the lubrication system is malfunctioning and/or not functioning at all. For example, the pressurized lubrication system may not operate properly when the pressure drops below the threshold pressure limit. Maintaining a properly functioning lubrication system is critical to the safety service life of the aircraft.
Pressurized lubrication systems can help to dissipate heat from and maintain the service life of a drive system. Pressurized lubrication systems, however, can sometimes fail resulting in a loss of lubrication (LOL). If the design of gears in the gearbox rely on the pressurized lubrication system to, e.g., maintain proper operating temperature, then any failure such as LOL could cause result in a catastrophic failure of the gears in the gearbox and could hinder the ability of an aircraft to remain in flight. LOL is characterized, for example, by the pressurized lubrication system reaching an operating pressure that is at or below the threshold pressure limit, for example, about 20 PSI, about 10 PSI, or about zero PSI. LOL can be caused, e.g., by failure of a pump to create the pressure for the pressurized lubrication system, a failure of an engine that supplies power to the pump, and/or by a leak in the pressurized lubrication system that allows the lubricant to escape from the pressurized lubrication system. Some aviation regulations require that an aircraft's pressurized lubrication system remain operable for a specified amount of time after LOL. As a result, some aircraft use redundant pressurized lubrication systems to reduce the likelihood of LOL, e.g., in one portion of the system from affecting other portions of the system. Such redundancy can be financially costly and can add weight to the aircraft, which can reduce flight and fuel efficiently.
A solution disclosed herein includes a hybrid lubrication system, a portion of which is pressurized and a portion of which is non-pressurized, to lubricate a drive system. The pressurized portion of the hybrid lubrication system uses pressure to lubricate the drive system. Advantageously, the non-pressurized portion of the hybrid lubrication system passively collects lubricant indirectly from the pressurized portion and uses motion of the drive system components themselves to disperse the lubricant instead of using pressure. The embodiments described throughout this disclosure provide numerous technical advantages including that the non-pressurized portion of the hybrid lubrication system can continue to provide lubricant to a portion of a drive train even after the pressurized portion of the hybrid lubrication system is no longer able to supply lubricant, e.g., due to a loss of lubricant event. For example, a non-pressurized lubrication system can include a reservoir to catch a portion of the lubricant from a pressurized lubrication system. A drive system component such as a gear or a driveshaft is operable to disperse the lubricant across components of the drive system based on the drive system component rotating through the portion of the lubricant.
In some embodiments, the non-pressurized lubrication system 328 includes a shroud 330. The shroud 330 confines the lubricant 320d as it is dispersed from the reservoir 318 by the gear 306c. The shroud 330 can help the reservoir 318 to catch the portion of the lubricant 320d from the pressurized lubrication system 326. For example, overspray of lubricant from the nozzles 312a and 312b can reach an outer surface of the shroud 330. The lubricant can drip down the outer surface of the shroud 330 to the reservoir 318 where it can collect and form the portion of the lubricant 320d. In addition, the shroud 330 can help to reserve the portion of the lubricant 320d for use in the non-pressurized lubrication system 328 separate from the pressurized lubrication system 326. As the gear 306c rotates through the portion of the lubricant 320d, it can be thrown in all directions around the gear 306c enabling it to reach the gear 306b and/or gear 306a. In turn, the other gears 306a and/or 306b may throw some of the lubricant in all directions around the gears 306a and/or 306b. The shroud 330 can prevent the portion of the lubricant 320d from being ejected from the non-pressurized lubrication system 328 due to being thrown from the gears 306a, 306b, and/or 306c. An inner surface of the shroud 330 is a barrier that can catch lubricant thrown from the gears 306a, 306b, and 306c. The lubricant can drip down the inner surface of the shroud 330 back to the reservoir 318, where it can be repeatedly used by the non-pressurized lubrication system 328. Because the shroud 330 retains the portion of the lubricant 320d within the non-pressurized lubrication system 328 and, at least in partially, separates it from the pressurized lubrication system 326, the non-pressurized lubrication system 328 can continue to lubricate the gears 306a, 306b, and 306c during a LOL in the pressurized lubrication system 326. The portion of the lubricant 320d can remain within the safety of the shroud 330 (and accessible for use by the non-pressurized lubrication system 328) even after the pressurized lubrication system 326 runs out of lubricant. In some examples, the non-pressurized lubrication system 328 can continue to operate for over 30 minutes after the pressurized lubrication system 326 runs out of lubricant.
While the non-pressurized lubrication system 328 is illustrated in
A lubricant is a substance introduced to reduce friction between moving surfaces. Examples of lubricants can include oil, biolubricants derived from plants and animals, synthetic oils, solid lubricants, and aqueous lubricants. Example lubricants may include oils meeting United States Military specification MIL-PRF-23699 (5cSt), United States Department of Defense (DoD) specifications DOD-L-7808 (3-4cSt) and DOD-PRF-85734 (5cSt), and other oils in the 9cSt to 10cSt viscosity range. The drive system 300 may include one or more lubrication systems to provide lubricant to sets of gears 304 and 306 and/or other the mechanical components.
Gears, bearings, and other mechanical components of drive system 111 are subject to wear and heat generation due to contact with other components. These mechanical components may be lubricated to reduce friction and transfer heat away from the components. Lubrication is the process or technique employed to reduce wear of one or both surfaces in close proximity, and moving relative to each other, by interposing a substance, such as a lubricant, between the surfaces to help carry the load (pressure generated) between the opposing surfaces and to help transfer heat away from the surfaces. The drive system 111 is an example of the drive system 300 and, therefore, includes a hybrid lubrication system as described with respect to
The drive system 111 includes the gearbox 129, which is coupled to and transmits power to each of the spiral bevel gearbox 127, a lubrication system pump 512, a driveshaft 504, a generator output 516, a blower gearbox 518, a hydraulic pump output 510, and an interconnect drive shaft 131. The lubrication system pump 512 generates pressure to pump a lubricant through a pressurized lubrication system. The driveshaft 504 is coupled to the spindle gearbox 133 and outputs power that is transmitted to the rotor blades. The generator output 516 powers a generator such as a direct current (DC) generator for supplying electrical power to components onboard an aircraft. The blower gearbox 518 can be mounted to interconnect gearbox 412 and can be configured to provide torque to the oil cooler blower fan, which may be used to draw in air for lubricant temperature reduction. The hydraulic pump output 510 can provide hydraulic power, e.g., for a control system such a cyclical and/or collective flight controls. The interconnect drive shaft 131 can be configured to provide a torque path that enables a single engine to provide torque to both drive systems 111 and 113 in the event of a failure of one of the engines 137 and 139.
The gearbox 129 includes a housing comprising housing portions 502a and 502b, which are attached to another to enclose the gears of the gear train that provide power to the aforementioned systems. The housing portions 502a and 502b form a cavity surrounding the gear train. The gear train includes gears 520, 522, 524, 526, 532, 528, 534, 536, 538, and 540. Each of the gears includes a gear shaft about which the gear rotates and a plurality of teeth that are operable to mate with one or more adjacent gears to transfer power between one another. As is shown, for example, in
During operation, the gears transmit power between one another based on receiving torque which causes the gear to rotate.
The hybrid lubrication system 570 of
The shroud 702 confines the lubricant from the pool 556 as it is dispersed from the reservoir 542 by the gear 536. The shroud 702 can help the reservoir 542 to catch the pool 556 of the lubricant from the pressurized lubrication system 580. For example, overspray of lubricant from the pressurized lubrication system 580 can reach an outer surface of the shroud 702. The lubricant can drip down the outer surface of the shroud 702 to the reservoir 542 where it can collect and form the pool 556 of the lubricant. In addition, the shroud 702 can help to reserve the pool 556 of the lubricant for use in the non-pressurized lubrication system 720 and separate it from the pressurized lubrication system 580. As the gear 536 rotates through the the pool 556 of the lubricant, it can be thrown in all directions around the gear 536 enabling it to reach other gears in the gear train 552. In turn, the other gears in the gear train 552 may throw some of the lubricant in all directions around each gear. The shroud 702 can prevent the pool 556 of the lubricant from being ejected from the non-pressurized lubrication system 720 due to being thrown from the gears in the gear train 552. An inner surface of the shroud 702 is a barrier that can catch lubricant thrown from the gears in the gear train 552. The lubricant can drip down the inner surface of the shroud 702 back to the reservoir 542, where it can be repeatedly used by the non-pressurized lubrication system 720. Because the shroud 702 retains the pool 556 of the lubricant within the non-pressurized lubrication system 720 and separate from the pressurized lubrication system 580, the non-pressurized lubrication system 720 can continue to lubricate the gears in the gear train 552 during a LOL in the pressurized lubrication system 580. The pool 556 of the lubricant can remain within the safety of the shroud 702 (and accessible for use by the non-pressurized lubrication system 720) even after the pressurized lubrication system 580 runs out of lubricant. In some examples, the non-pressurized lubrication system 720 can continue to operate for over 30 minutes after the pressurized lubrication system 580 runs out of lubricant.
In addition, the system 900 of the
The example reservoir configurations illustrated in the embodiments of
The hybrid lubrication system 1250 lubricates the gears using the pressurized lubrication system 1230 and the non-pressurized lubrication system 1240. The pressurized lubrication system 1230 is an active system that requires direct power to maintain the pressure in the system to propel the lubricant. The non-pressurized lubrication system 1240 is a passive system that relies on the movement of the gears to disperse the lubricant and does not require direct power to propel the lubricant. The pressurized lubrication system 1230 includes nozzles 1214a, 1214b, and 1214c, each of which is operable to spray lubricant 1215a, 1215b, 1215c, and 1215d, respectively, onto the gears. The nozzles 1214a, 1214b, and 1214c are supplied lubricant by pressurized tubes 1213a, 1213b, 1213c, and 1213d, respectively. The nozzle 1214a is directed toward an intersection of the gears 1206a and 1208a and sprays the lubricant 1215a on the gears 1206a and 1208a. The nozzle 1214b is directed toward an intersection of the gears 1206b and 1208b and sprays the lubricant 1215b on the gears 120b and 1208b. The nozzle 1214c is directed toward the gear 1212b and sprays the lubricant 1215c on the gear 1212b. As the nozzles 1214a-c spray the gears with the lubricant, some of the lubricant may travel to other locations in the main rotor gearbox 213. The non-pressurized lubrication system includes a reservoir 1222, which is operable to catch a portion of the lubricant from the pressurized lubrication system. The reservoir 1222 operates similar to the reservoir 542 as described with respect to
Although several embodiments have been illustrated and described in detail, numerous other changes, substitutions, variations, alterations, and/or modifications are possible without departing from the spirit and scope of the present disclosure, as defined by the appended claims. The particular embodiments described herein are illustrative only, and may be modified and practiced in different but equivalent manners, as would be apparent to those of ordinary skill in the art having the benefit of the teachings herein. Those of ordinary skill in the art would appreciate that the present disclosure may be readily used as a basis for designing or modifying other embodiments for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. For example, certain embodiments may be implemented using more, less, and/or other components than those described herein. Moreover, in certain embodiments, some components may be implemented separately, consolidated into one or more integrated components, and/or omitted. Similarly, methods associated with certain embodiments may be implemented using more, less, and/or other steps than those described herein, and their steps may be performed in any suitable order.
Numerous other changes, substitutions, variations, alterations, and modifications may be ascertained to one of ordinary skill in the art and it is intended that the present disclosure encompass all such changes, substitutions, variations, alterations, and modifications as falling within the scope of the appended claims.
In order to assist the United States Patent and Trademark Office (USPTO), and any readers of any patent issued on this application, in interpreting the claims appended hereto, it is noted that: (a) Applicant does not intend any of the appended claims to invoke paragraph (f) of 35 U.S.C. § 112, as it exists on the date of the filing hereof, unless the words “means for” or “steps for” are explicitly used in the particular claims; and (b) Applicant does not intend, by any statement in the specification, to limit this disclosure in any way that is not otherwise expressly reflected in the appended claims.
Claims
1. An aircraft gearbox comprising:
- a plurality of gears operable to rotate based on torque received from a driveshaft, the plurality of gears comprising a first gear and a second gear; and
- a hybrid lubrication system operable to lubricate the plurality of gears, the hybrid lubrication system comprising: a pressurized lubrication system comprising a nozzle operable to spray a lubricant onto the first gear; and a non-pressurized lubrication system comprising a reservoir operable to catch a portion of the lubricant from the pressurized lubrication system, wherein the second gear is operable to disperse the lubricant onto others of the plurality of gears based on rotating through the portion of the lubricant.
2. The aircraft gearbox of claim 1, wherein the reservoir conforms to a shape of the second gear.
3. The aircraft gearbox of claim 1, wherein the reservoir is operable to surround a portion of only the second gear.
4. The aircraft gearbox of claim 1, wherein the first gear is operable to transmit power to a rotor on a rotorcraft and the second gear is operable to transmit power to an auxiliary system on the rotorcraft.
5. The aircraft gearbox of claim 1, wherein the plurality of gears comprises:
- a first set of gears comprising the first gear, and
- a second set of gears comprising the second gear; and
- wherein the pressurized lubrication system is operable to spray the lubricant onto the first set of gears and the second gear is operable to disperse the lubricant onto others of the second set of gears based on rotating through the portion of the lubricant.
6. The aircraft gearbox of claim 5, wherein the pressurized lubrication system comprises a plurality of nozzles each corresponding to one of the first set of gears.
7. The aircraft gearbox of claim 5, wherein the non-pressurized lubrication system comprises a plurality of reservoirs each corresponding to a different one of the second set of gears.
8. The aircraft gearbox of claim 5, wherein each gear in the first set of gears is operable to mesh with only the first set of gears, and each gear in the second set of gears is operable to mesh with only the second set of gears.
9. An aircraft comprising:
- an engine;
- a driveshaft coupled to the engine; and
- a gearbox comprising: a plurality of gears operable to rotate based on torque received from the driveshaft, the plurality of gears comprising a first gear and a second gear; and a hybrid lubrication system operable to lubricate the plurality of gears, the hybrid lubrication system comprising: a pressurized lubrication system comprising a nozzle operable to spray a lubricant onto the first gear; and a non-pressurized lubrication system comprising a reservoir operable to catch a portion of the lubricant from the pressurized lubrication system, wherein the second gear is operable to disperse the lubricant onto others of the plurality of gears based on rotating through the portion of the lubricant.
10. The aircraft of claim 9, wherein the reservoir conforms to a shape of the second gear.
11. The aircraft of claim 9, wherein the reservoir is operable to surround a portion of only the second gear.
12. The aircraft of claim 9, wherein the plurality of gears comprises:
- a first set of gears comprising the first gear, and
- a second set of gears comprising the second gear; and
- wherein the pressurized lubrication system is operable to spray the lubricant onto the first set of gears and the second gear is operable to disperse the lubricant onto others of the second set of gears based on rotating through the portion of the lubricant.
13. The aircraft of claim 12, wherein the pressurized lubrication system comprises a plurality of nozzles each corresponding to one of the first set of gears.
14. The aircraft of claim 12, wherein the non-pressurized lubrication system comprises a plurality of reservoirs each corresponding to a different one of the second set of gears.
15. A method comprising:
- providing an aircraft gearbox comprising a plurality of gears, the plurality of gears comprising a first gear and a second gear; and
- lubricating the plurality of gears with a hybrid lubrication system comprising a pressurized lubrication system and a non-pressurized lubrication system, wherein the lubricating comprises: spraying, by a nozzle in the pressurized lubrication system, a lubricant onto the first gear; catching, by a reservoir in the non-pressurized lubrication system, a portion of the lubricant from the pressurized lubrication system; and dispersing the lubricant onto others of the plurality of gears based on the second gear rotating through the portion of the lubricant.
16. The method of claim 15, wherein the reservoir conforms to a shape of the second gear.
17. The method of claim 15, further comprising:
- transmitting, by the first gear, power to a rotor on an aircraft; and
- transmitting, by the second gear, power to an auxiliary system on the aircraft.
18. The method of claim 15, wherein the plurality of gears comprises:
- a first set of gears comprising the first gear, and
- a second set of gears comprising the second gear; and
- further comprising: spraying, by the pressurized lubrication system, the lubricant onto the first set of gears; and dispersing the lubricant onto others of the second set of gears based on the second gear rotating through the portion of the lubricant.
19. The method of claim 18, wherein the pressurized lubrication system comprises a plurality of nozzles, and further comprising:
- spraying, by each of the plurality of nozzles, the lubricant onto one of the first set of gears.
20. The method of claim 18, wherein the non-pressurized lubrication system comprises a plurality of reservoirs corresponding to a different one of the second set of gears.
Type: Application
Filed: Oct 5, 2018
Publication Date: Apr 9, 2020
Inventor: Russell L. Mueller (Coppell, TX)
Application Number: 16/152,919